CUSTOM MATCHED JOINT PROSTHESIS REPLACEMENT

• US 20160296289A1
• Filed: 06/20/2016
• Published: 10/13/2016
• Est. Priority Date: 03/15/2013
• Status: Abandoned Application

• Current Assignee: Concepto, LLC
• Original Assignee: Concepto, LLC
• Inventors: Choudhury, Sambhu, Lynch, Sean, Sanchez, Arturo David, Law, Andrew Ryan
• Application Number:
  US15/186,853
• Publication Number:
  US 20160296289A1
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: A61B 2034/108 Computer aided selection or customisation of medical implants or cutting guides
• CPC Class Codes: A61B 34/10 Computer-aided planning, simulation or modelling of surgical operations
• CPC Class Codes: A61F 2/30724 Spacers for centering an implant in a bone cavity, e.g. in a cement-receiving cavity
• CPC Class Codes: A61F 2/30942 for designing or making customized prostheses, e.g. using templates, CT or NMR scans, finite-element analysis or CAD-CAM techniques
• CPC Class Codes: A61F 2/32 for the hip
• CPC Class Codes: A61F 2/34 Acetabular cups
• CPC Class Codes: A61F 2002/30448 using adhesives
• CPC Class Codes: A61F 2002/30449 the adhesive being cement
• CPC Class Codes: A61F 2002/3069 Revision endoprostheses
• CPC Class Codes: A61F 2002/30962 using stereolithography
• CPC Class Codes: A61F 2002/3208 Bipolar or multipolar joints, e.g. having a femoral head articulating within an intermediate acetabular shell whilst said shell articulates within the natural acetabular socket or within an artificial outer shell
• CPC Class Codes: A61F 2002/3479 Cage-like shells, e.g. hemispherical outer shells made of meridian strips or wires connected to an equatorial strip, rim or wire
• CPC Class Codes: A61F 2310/00029 Cobalt-based alloys, e.g. Co-Cr alloys or Vitallium
• CPC Class Codes: B22D 11/01 without moulds, e.g. on molten surfaces
• CPC Class Codes: B29C 64/112 using individual droplets, e.g. from jetting heads
• CPC Class Codes: B29C 64/386 Data acquisition or data processing for additive manufacturing
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: B33Y 30/00 Apparatus for additive manufacturing; Details thereof or accessories therefor
• CPC Class Codes: B33Y 50/02 for controlling or regulating additive manufacturing processes
• CPC Class Codes: C22C 19/07 based on cobalt
• CPC Class Codes: G05B 15/02 : electric

Abstract

An apparatus and method of fabricating a replacement prosthesis component for implantation into a patient by receiving a diagnostic scan of an implanted prosthesis component in the patient. A controller converts the diagnostic scan into a three-dimensional model of the implanted prosthesis. The controller automatically matches the three-dimensional model with a selected replacement part model that mates with the implanted prosthesis. The controller prepares a three-dimensional printing model of the selected replacement part model to a three-dimensional printer for fabricating a matching replacement part.

Claims

1. A method of fabricating a replacement prosthesis component for implantation into a patient, the method comprising:

receiving a diagnostic scan of an implanted prosthesis component in the patient;

converting the diagnostic scan into a three-dimensional model of the implanted prosthesis;

automatically matching the three-dimensional model with a selected replacement part model that mates with the implanted prosthesis; and

preparing a three-dimensional printing model of the selected replacement part model to a three-dimensional printer for fabricating a matching replacement part.

2. The method of claim 1, further comprising performing a computer tomography (CT) scan to create the diagnostic scan.

3. The method of claim 1, further comprising identifying the three-dimensional model to facilitate automatic matching by locating product identification indicia imprinted on a surface of the three-dimensional model.

4. The method of claim 1, further comprising identifying the three-dimensional model to facilitate automatic matching by performing geometric dimensioning and tolerance (GD&

T) analysis.

5. The method of claim 1, further comprising three-dimensional printing, by the three-dimensional printer, the three-dimensional printing model.

6. The method of claim 1, wherein:

the implanted prosthesis component comprises a secure acetabular shell implanted into a acetabular recess in a pelvis; and

the replacement prosthesis component comprises a hemispherical liner formed from a cast cobalt-chromium alloy and having an outer diameter sized for attachment inside the secure acetabular shell.

7. The method of claim 6, wherein the hemispherical liner comprises:

at least three spacers annularly displaced about an outer diameter of the hemispherical liner to define a uniform cement thickness with the secure acetabular shell; and

web shaped depressions formed circumferentially and longitudinally in the outer diameter of the hemispherical liner to receive cement.

8. The method of claim 7, wherein:

the at least three spacers comprise polymethyl methacrylate (PMMA); and

the at least three spacers comprise a first spacer attached to an apex of the hemispherical liner and at least three spacers annularly spaced at a midpoint of a radius of curvature of the outer diameter.

9. The method of claim 7, wherein:

the at least three spacers extend 0.5 mm from the outer diameter; and

the web shaped depressions are 0.75 mm deep.

10. The method of claim 6, wherein the hemispherical liner comprises a truncated radius of curvature limited to 165°

with respect to a center of articulating movement of a femoral head received in an articular head insert received in turn for dual mobility by the hemispherical liner.

11. An apparatus of fabricating a replacement prosthesis component for implantation into a patient, the apparatus comprising:

a memory containing three-dimensional information on more than one type of replacement prosthesis component;

a controller communicatively coupled to the memory and a three-dimensional printer, the controller;

receives a diagnostic scan of an implanted prosthesis component in the patient;

converts the diagnostic scan into a three-dimensional model of the implanted prosthesis;

automatically matches the three-dimensional model with a selected replacement part model that mates with the implanted prosthesis; and

prepares a three-dimensional printing model of the selected replacement part model to a three-dimensional printer for fabricating a matching replacement part.

12. The apparatus of claim 11, further comprising a CT scanner communicatively coupled to the controller to perform a computer tomography (CT) scan to create the diagnostic scan.

13. The apparatus of claim 11, wherein the controller identifies the three-dimensional model to facilitate automatic matching by locating product identification indicia imprinted on a surface of the three-dimensional model.

14. The apparatus of claim 11, wherein the controller identifies the three-dimensional model to facilitate automatic matching by performing geometric dimensioning and tolerance (GD&

T) analysis.

15. The apparatus of claim 11, further comprising the three-dimensional printer to receive three-dimensional printing model and to fabricate the selected replacement prosthesis component.

16. The apparatus of claim 11, wherein:

the implanted prosthesis component comprises a secure acetabular shell implanted into a acetabular recess in a pelvis; and

the replacement prosthesis component comprises a hemispherical liner formed from a cast cobalt-chromium alloy and having an outer diameter sized for attachment inside the secure acetabular shell.

17. The apparatus of claim 16, wherein the hemispherical liner comprises:

at least three spacers annularly displaced about an outer diameter of the hemispherical liner to define a uniform cement thickness with the secure acetabular shell; and

web shaped depressions formed circumferentially and longitudinally in the outer diameter of the hemispherical liner to receive cement.

18. The apparatus of claim 17, wherein:

the at least three spacers comprise polymethyl methacrylate (PMMA); and

the at least three spacers comprise a first spacer attached to an apex of the hemispherical liner and at least three spacers annularly spaced at a midpoint of a radius of curvature of the outer diameter.

19. The apparatus of claim 17, wherein:

the at least three spacers extend 0.5 mm from the outer diameter; and

the web shaped depressions are 0.75 mm deep.

20. The apparatus of claim 16, wherein the hemispherical liner comprises a truncated radius of curvature limited to 165°

with respect to a center of articulating movement of a femoral head received in an articular head insert received in turn for dual mobility by the hemispherical liner.